Some Aspects of Energy Efficiency

and Energy Conservation

in Power Generation Industry(Round Table discussion)

Conference on the Future of Energy in Enlarged Europe: Perspectives for R&D Co-operation

A contribution within the context of the Weimar Triangle

October 7- 8th, 2004, Warsaw

Krzysztof Badyda

INSTITUTE OF HEAT ENGINEERING

WARSAW UNIVERSITY OF TECHNOLOGYITChttp://www.itc.pw.edu.pl

Warsaw University of Technology (Politechnika Warszawska)

The Warsaw University of Technology (WUT) is the largest academic school of technology in Poland, employing 2.000 professors. The number of students is 30.000, most of them study full-time. There are 17 faculties covering almost all fields of science and technology.

The Institute of Heat Engineering is part of the Faculty of Power and Aeronautical Engineering (FPAE - MEiL) of the WUT.

Staff of the Institute - 130 persons, incl. 30 doctor students, and 25 technical and administration staff.

ITC General information

Institute of Heat Engineering: structure

Management: Prof. Janusz LewandowskiProf. Jerzy Banaszek - didactics and researchDr Tomasz Wiśniewski - technical aspects,

organisation and finance

Division of Refrigeration, Machines andEquipment for Chemical and Food Industry - Prof. Jerzy Sado

Division of Power Engineering - Prof. Andrzej Miller

Division of Thermodynamics - Prof. Roman Domański

Division of Aircraft Engines - Prof. Piotr Wolański

Division of Pumps, Drivers and Power Stations - Prof. Waldemar Jędral

ITC

ITC Division of Power Engineering: specialities

Scientific fundamentals of machine design and operation.

Apparatus and their sets in power engineering.

Development of methods for mathematical modelling and simulation of performance under design, off-design and transient conditions.

Objects• Utility and captive power plants• Steam and gas turbines• Combined and cogeneration sets• Digital simulators of power plant equipment – turbosets, boilers• New applications of distributed control systems• Clean coal and environment protection technologies• Hydrogen and fuel cells

ITCDivision of Power Engineering:partners/customers

• Transition Technologies (TT) – a company specialised in implementation of new computer technologies in power plant engineering

• Alstom Power Poland – steam and gas turbine manufacturer

• Vattenfall – owner of the largest combined heat and power plant in Europe (Siekierki – 620 MWel and 2000 MWth)

• BOT Group – owner of the largest power plant in Poland (capacity of 12370 MWel)

• PKN ORLEN – owner of the largest oil refining and petrochemical plant in Poland, and of the largest captive CHP plant in Poland

• Power plants and combined heat and power plants (utility and captive, including the distributed power sector)

ITC Division of Power Engineering:international partners/co-operation

• National Institute of Advanced Industrial Science and Technology, Tsukuba, Japan

• San Diego State University, California, USA

• Kharkov University of Technology, Ukraine

• Moscow Power Engineering Institute (MEI), Russia

• University of Western Australia, Perth, Australia

• International Industrial Assessment Center DOE,Philadelphia USA (energy audits in industry)

ITC• Modernisation of turbines: adapting of flow systems to off-design

operating conditions

• Modernisation of boilers: adapting to off-design operating conditions and/or increase of efficiency

• Energy audits for power and other industrial plants, proposals of production process modernisation or modification

• Modelling of energy and technology systems, process losses determination

• Optimisation of load distribution in combined heat and power plants using automatic model construction (DCS)

• New applications of distributed control systems in power generation industry

Division of Power Engineering:Typical projects in the area of energy saving (realised in co-operation with industry)

Energy auditat Siekierki Combined Heat and Power Plant

Sankey diagram of energy flows for part of the Siekierki CHP plant in typical conditions

ITC

Boiler driving with neural networksin Połaniec Power Plant

PW1...6

WM

1...6

MW1...6Secondary air

OFA

Total air

Secondarysteam

Primary steam

Concentration L,RCOO2

NOx

Combustion temperature Temperatures

and their differences

Outlet gases temperature L,R

ITC

Optimisation results

• Reduction of NOx emission by approx. 15-25%

• Efficiency increased by approx. 0.2 - 0.7%

• Elimination of CO

• Number of flammable parts not increased

• Economic operation of actuators

• Safe switching over (supervision system)

• Improved system reliability

ITC

Optimisation of load distribution at a CHP plantITC

B1

gasoil

B5

gasoil

B3

gasoil

B2

gasoil

B6

gasoil

B7

gasoil

B4

gasoil

12.8 MPa

0.12 MPa

3.4 MPa1.8 MPa

0.75 MPa

TG1 TG2 TG3 TG4 TG5

Simplified heat diagram

ITC Optimisation results

0 5 1 0 1 5

1 8 0

1 9 0

2 0 0

0 5 0 1 0 00 .0 8

0 .1 0

0 .1 2

0 .1 4

t [h]

BBs

t [h]

Nel[MW]

Generated electric power Relative obtainable fuel savings

Hydrogen Turbine ProjectWE-NET – co-operation with Japan

Modified New Rankine Cycle (MNRC)proposal of ITC

c = 84,5%

R = 66,4%

HHV = 66,4%

LHV = 77,2%

HPT MPT LPT

H2 O2 H2H2 O2O2

ITC

Pressurised fluidised bed boilerinstallation diagramITC

Power generation industry in Poland

Installed capacity: 35000 MW.

Electricity generation of distributed power generation sector: very low – installed capacity (end of 2002 – excl. industrial power): wind power 31 MW, biogas 42 MW, small water plants 492 MW. Contribution to the energy production: 0.2%.

Needed intensive development of electricity sources using renewable energy.

Relatively high rate of electricity production combined with heat generation.

Combined heat and power plant capacity: domination of large plants.

Domination of coal in the energy sector.

ITC

Cogeneration electricity production rate in Poland from 1985 to 2002

Average for EC („old” 15) in 2000: about 10%.

198 5 19 90 1 995 2000 200 5Y ea r

10

12

14

16

18

20

El c

omb/

El to

tal[%

]ITC

0

10

20

30

40

50

60

Elec

trici

ty in

cog

ener

atio

n ra

te [%

]Rate of combined electricity production 2001

(selected „old” and „new” EC members)ITC

Domination of coal in the electricity production in Poland

Hard coal and lignite: 93% !!

ITC

Energy efficiency and energy savings: proposals of co-operation

• Research on advanced power systems with use of hydrogen, esp. two-source systems

• Research and analysis of clean coal technologies

• Analysis of new concepts of zero CO2 emission power generation technologies

• Fuel cell hybrid systems - research and development

• Implementation of mathematical modelling of power installations in collaboration with distributed control systems (DCS)

• New concept of power plant information system

ITC

Recently, the interest in investigation on ultra-efficient electricity generation systems is focused on the application of fuel cells. From distributed generation point of view (200 kW to 20 MW), two types of fuel cells are considered: Molten Carbonate Fuel Cell and Solid Oxide Fuel Cell. These types of fuel cells require more complex configuration of power plant cycle for proper operation.

The introduction of fuel cell into power plant cycle creates a hybrid system. The research and development of these hybrid systems is a key for future use of this kind of energy sources. The focus of investigations should be laid on design, off-design and dynamic simulations of hybrid systems.

ITC Fuel cell hybrid systems

The new abilities for data transfer and recording within the DCS make the implementation of different application software possible. The software co-operating with DCS can also generate information for the system. That makes simulation of operation of controlled installation elements possible.

Examples of projects of implementation of mathematical modelling for DCS applications, realised in our Institute: digital simulator of a back-pressure extracting steam turbine, digital simulator of a steam boiler, optimisation of load distribution in captive and utility power plants (combined heat and power), software products supporting operation of power plants .

Implementation of mathematical modelling of power installations in collaboration with distributed control systems (DCS)ITC

Distributed control systems (DCS) are installed in all major power and industrial plants. The automatic collection of technical data and computer processing ability open and even force new opportunities of process control and maintenance. On the other hand, a new concept of management information system (MIS) organisation in power plants and companies should be done. The new policy on the Polish energy market strongly speeds the consolidation of generators into power concerns up. Therefore, in several enterprises kind of remote management centres will be created. New MISs need to be used for them. A concept of complex utilisation data warehouse and “power portal” (internet type GUI), which seems to be the most suitable for this kind of application, was presented in multiple papers.

ITC New concept of power plant information system

THANK YOU

FOR YOUR KIND ATTENTION !

Conference on the Future of Energy in Enlarged Europe: Perspectives for R&D Co-operation

A contribution within the context of the Weimar Triangle

October 7- 8th, 2004, Warsaw

Krzysztof Badyda

INSTITUTE OF HEAT ENGINEERING

WARSAW UNIVERSITY OF TECHNOLOGYITC

Krzysztof Badyda D.Sc., Ph.D.ProfessorWarsaw University of TechnologyInstitute of Heat EngineeringNowowiejska 25 Str.pl 00-665 Warszawatel. (+48-22) 660-5281, 825-29-01fax. (+48-22) 825-25-65e-mail: badyda@itc.pw.edu.pl

http://www.itc.pw.edu.pl